System, method, process and nutrient-rich product derived from wine derivatives

ABSTRACT

Described herein is a system, methods, processes and nutrient-rich products-by-process, which are generated by the conversion of winery derivatives into nutrient-rich products in an ecological manner. Integration of this system into a winery assists the winery to manage its previously-considered waste nutrient-rich products in an ecological manner, which can also optionally provide them with a novel revenue stream. The system, methods, and processes are used to convert winemaking derivatives into bioactive nutrient-rich products comprising antioxidants and other bioactive molecules that reside within the marc and lees. These nutrient-rich products can be used as natural flavour, texture and color enhancers, in addition to nutritional ingredients to fortify processed foods and consumer recipes. They can also be used as health supplements and in the cosmetic industry.

FIELD

This disclosure pertains to the field of fermenting wine derivativesinto useful nutrient-rich products.

SUMMARY

Described herein is a system, methods, processes and nutrient-richproduct-by-process, which are generated by the conversion of wineryderivatives into nutritionally beneficial supplements in an ecologicalmanner. Integration of this system into a winery assists the winery tomanage its previously-considered waste nutrient-rich products in anecological manner, which can optionally bring them a novel separatenovel revenue stream. The system, methods, and processes are used toconvert winemaking derivatives into nutrient-rich products comprisingantioxidants and other bioactive molecules, which reside within the marcand lees. These nutrient-rich products can be used as natural flavour,texture and color enhancers, in addition to nutritional ingredients tofortify processed foods and consumer recipes. They can also be used ashealth supplements and in the cosmetic industry,

BACKGROUND

The winemaking industry produces millions of tons of leftovers andresidues, which represent an ecological and economical waste managementissue for the wineries. The leftovers and residues include organicwastes, inorganic wastes, wastewater, and emission of greenhouse gases(CO2, volatile organic compounds, etc.) Due to growing issues aroundgroundwater and soil contamination, wineries send most of it to thelandfill, costing the winery fees for bin drop-off, removal, haulage andtipping fees in addition to winery management costs. Addressing theseissues in an appropriate manner places a financial burden on most of thewineries, especially the smaller ones.

One resource often used by winemaking industry is the intermediate bulkcontainer (IBC), which are also known as an IBC tote, IBC tank, IBC, orpallet tank. IBCs are ideal for storing and transporting nutrient-richproducts such as liquids, semi-solids, pastes, solvents, or granulatesubstances (food, chemicals, pharmaceuticals, etc.) in large quantities.The concept of the IBC was patented in 1993, and is described in U.S.Pat. No. 5,260,414, of which there are two main categories: flexibleIBCs and rigid IBCs.

Rigid IBCs are stackable, reusable, versatile containers with anintegrated pallet base mount that provides forklift and/or pallet jackmaneuverability. Most IBCs are cube-shaped and this cube-shapedengineering contributes to the packaging, stacking, storing, shipping,and overall space efficiency of intermediate bulk containers. Almost allrigid IBCs are designed so they can be stacked vertically one atop theother using a forklift.

The support structure/containers can be made from metal (stainlesssteel), plastic (high-density polyethylene), or a composite construction(galvanized steel and plastic) of the two materials. The IBC tank can bemade of plastic, stainless steel, and carbon steel tanks The IBC tankcapacities generally used are often 1,040 and 1,250 litres (275 and 330US gal).

The most widely utilized and known IBC is the limited re-use, caged IBCtote container. Caged IBC totes are composite intermediate bulkcontainers—a white/translucent plastic container (typically high-densitypolyethylene) contained and protected by a tubular galvanized steelgrid, common. Most have a built-in tap (valve, spigot, or faucet) at thebase of the container to which hoses can be attached, or through whichthe contents can be poured into smaller containers.

The winemaking process generates two major residues, which can beharvested. The major residues from the winemaking process after thede-stemming and crush steps are known as derivatives. Derivativescomprise grape marc (pomace) and lees. For every two bottles of winemade, typically the equivalent of one bottle of derivatives is produced.Winery derivatives comprise:

-   -   a) marc (pomace) consisting of grape skin, grape pulp and grape        seed derived from varietal grapes, which have been crushed and        pressed as part of the winemaking process; and    -   b) lees consisting of spent wine yeast, tartaric acid, grape        skin pigment and grape pulp sediment, which have been extruded        from the wine after fermentation and again after aging.

Grape marc provides substantial nutritional potential as supplements andto fortify food. For example, 15 grams (˜1 tbsp.) of powdered derivativemay contain up to 900 mg of phenols, 150 mg of tannins (catechin), 2000mg of protein, 180 mg of potassium, 120 mg of magnesium, 4 mg of iron,4% DV of riboflavin, 125% DV of vitamin E and 3% DV of vitamin K).

In general, wine lees is residue that forms at the bottom of winecontainers consisting of: 1) first and second-fermentation lees, whichare formed during the alcoholic and malolactic fermentations,respectively (herein, lees); 2) during storage or after treatments(herein, first-rack lees); and 3) aging wine lees formed during wineaging in wood barrels collected after the filtration or centrifugationof the wine (herein, second-rack lees), The main characteristics of winelees are acidic pH (between 3 and 6), a chemical oxygen demand above30,000 mg/L, potassium levels around 2500 mg/L, and phenolic compoundsin amounts up to 1000 mg/L Approximately 30% of red wine lees areprotein that is produced from yeast cell wall material, which contains30-60% 3-b-D-glucan in dry weight.

Derivatives are used in livestock and poultry feed to extend theshelf-life of milk, dairy by-nutrient-rich products, and meat. There isextensive research on the anti-microbial benefits as a replacement forantibiotics for poultry and livestock. There is even research showingthat it can cut bovine methane emissions by 30%

Although there is an identified market for these derivatives, thecurrent processes used to transform it into shelf-stable nutrient-richproducts creates a carbon footprint, is prohibitively expensive andcauses significant loss in the quality in the derivatives.

The extraction of useful nutrient-rich products from wine derivatives isknown in the art. However, most of these processes seek to isolate aspecific compound, require multiple steps, and/or require drying thenutrient-rich product into a powder that can be easily sold in capsule,tablet, powder form, etc. Drying the nutrient-rich product and/or usingchemical processes to isolate nutrient-rich products therefrom candiminish the bioavailability of the biomolecules desired in the finalnutrient-rich products.

It is widely recognized that the nutrient value of foods has beendiminishing since at least the 1950's, such that a need has developedfor cost effective strategies to fortifying foods in the food supply,incorporating the resources of a winery to make adaptation easilyaccessible for the business.

There is tremendous value in monetizing these derivatives. The issuetoday is economics; finding a cost-effective way to process derivativesin an ecological manner, without losing flavour and nutrition.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 provides an aerial view of one embodiment of the system,illustrating one aspect of the integration of the system into a winery.

FIG. 2 illustrates one embodiment of the steps involved in separatingmarc and lees from a general winemaking process and inserting them intothe system and processes described herein.

FIG. 4 is a flow diagram showing one embodiment of the steps ofderivative conversion presented in FIG. 2, in addition to intermediatesand nutrient-rich products generated throughout. As indicated at 226,the description of the process continues in FIG. 4.

FIG. 5 is a continuation of the flow diagram of FIG. 4, continuing at226.

FIG. 6 provides one embodiment of the steps of separating marc and leesfrom a general winemaking process and inserting them into the system andprocesses described herein, wherein the process includes the additionoff second-rack lees.

FIG. 7 is a flow diagram showing one embodiment of the steps ofderivative-conversion presented in FIG. 6 in addition to intermediatesand nutrient-rich products generated throughout. As indicated at 226,the description of the process continues in FIG. 8

FIG. 8 is a continuation of the flow diagram of FIG. 7, continuing at226.

FIG. 9 illustrates one embodiment of processing container within thissystem.

FIG. 10 shows one example of one embodiment of the integration of aseries of processing containers into a winery facility, which includesone or more protective covers.

FIG. 11 provides one example of one embodiment illustrating theintegration of the system with the work-flow of a winery.

FIG. 12 provides one embodiment of a method of performing the businessmethod described herein.

DETAILED DESCRIPTION

Described herein is a system, methods, processes and nutrient-richproducts-by-process, which are generated by the conversion of wineryderivatives into nutritionally beneficial supplements in an ecologicalmanner. Integration of this system into a winery assists the winery tomanage its previously-considered waste nutrient-rich products in anecological manner, which can optionally provide them a novel revenuestream. The system, methods, and processes are used to convertwinemaking derivatives into bioactive nutrient-rich products comprisingantioxidants and other bioactive molecules that reside within the marcand lees. These nutrient-rich products can be used as natural flavour,texture and color enhancers, in addition to nutritional ingredients tofortify processed foods and consumer recipes. They can also be used ashealth supplements.

One embodiment comprises a system for integration into a wine-makingfacility and its processes comprising: one or more processingcontainers, designed for ease of use by winery staff, ease of storageduring processing, efficacy, monitoring and security ofderivative-conversion process to at least the stage of fermented puree;instructions for the role of winery staff to participate in the processof derivative-conversion into fermented puree; and optionally, microbialformulations designed to meet the fermentation objectives of anutrient-rich product generated by the derivative-conversion process.One embodiment of the system comprises the one or more processingcontainers in which a version of a food-grade intermediate bulkcontainer has been modified by generating a retractable lid therein. Oneembodiment of the system comprises one or more processing containerswhich have been modified by incorporating aerating means attachedthereto. One embodiment of the system comprises one or more processingcontainers which have been modified by incorporating process monitoringmeans attached thereto.

One embodiment of the process for converting marc, first-rack lees andoptionally second-rack lees derived from the winemaking process intorefined nutrient-rich products comprises the steps of: a) transferringmarc to a processing container; b) hydrating marc until berries swell;c) grinding hydrated marc to generate meal; d) optionally inoculatingmeal with a microbial formulation; e) fermenting inoculated meal togenerate fermenting meal; f) transferring first-rack lees to theprocessing container; g) emulsifying the first first-rack lees andfermenting meal to generate a puree; h) optionally inoculating thepuree; i) fermenting said puree to generate a fermented puree; j)refining fermented puree to generate a refined nutrient-rich product; k)optionally stabilizing refined product to generate stabilizednutrient-rich product; and 1) optionally packaging the stabilizednutrient-rich product. One embodiment of the process comprisesinoculating with the microbial formulation selected from Acetobacter,and/or Gluconobacter and/or other known acetic acid bacteria and/orfungus inoculants. One embodiment of the process incorporates the use ofenzymes, which may be added the fermenting meal. One embodiment of theprocess according to claim 4, wherein methane emissions that wouldotherwise be caused by disposal of marc and lees in buried landfills iseliminated or significantly reduced. One embodiment of the processincludes a nutrient-rich product substantially produced thereby. Oneembodiment of the process includes the nutrient-rich product comprisesvarietal grape skin, varietal grape seed, and winemaking sediment.

One embodiment of the method of converting winery derivatives intobioactive products comprising the steps of: a) a business delivers oneor more processing containers to a winery prior to crush; b) winerystaff transfers marc to one or more processing container(s); c) winerystaff rehydrates marc until berries swell, grinds the biomass into ameal, inoculates with microbial s, and allows it to ferment at thewinery facility; d) winery staff transfers first-rack lees to the one ormore processing containers comprising fermenting meal; e) winery staffemulsifies the first-rack lees and fermenting meal to generate puree,inoculates the puree and allows it to ferment at winery facility; f)winery staff monitors the progress of fermenting puree and notifies thecompany when the fermentation has completed; and g) the business picksup the one or more processing containers and continues processing thefermented puree at the company facility. One embodiment of the methodcomprises using Acetobacter, and/or Gluconobacter and/or other knownacetic acid bacteria and/or fungus inoculants in the microbialformulation. One embodiment of the method comprises the use of enzymes,which may be added the fermenting meal. One embodiment of the methodcomprises eliminating or significantly reducing methane emissions thatwould otherwise be caused by disposal of marc and lees in buriedlandfills. One embodiment of the method comprises a nutrient-richproduct substantially produced by the method. One embodiment of themethod comprises a nutrient-rich product comprising varietal grape skin,varietal grape seed, and winemaking sediment made thereby.

An Overview of the Derivative-Conversion Process Integrated withWinemaking Processes

With reference to FIGS. 2 and 5, this section of the description willintroduce an overview for two embodiments the derivative-conversionprocess alongside and integrated with a general description for winemaking processes. The subsequent section, with reference to FIGS. 3, 4,6 and 7, will describe further details of these steps, without referenceto the general winemaking processes. One skilled in the art wouldappreciate and know that this system, methods, processes andnutrient-rich products made thereby 200 could be adapted for wineriesproducing fruit wine. In one embodiment, the system 200 is integratedwith a winery that produces fruit wine. One embodiment, the system 200is integrated with a winery that produces both grape wine and fruitwine. In one embodiment, the system, methods, processes andnutrient-rich products made thereby 200 include the derivatives producedby both the grape winemaking process and the fruit winemaking process.

With reference to FIGS. 2 and 5, embodiments of the process for makingthese bioactive nutrient-rich products are described below. The steps ofa traditional general winemaking process are labeled with alphacharacters (A, B, C, etc.). The steps within embodiments of the generalderivative-conversion process for generating bioactive nutrient-richproducts are labelled with numeric characters (1, 2, 3, etc.).

In Step A 102, the winery either picks or buys varietal wine grapes thatare optimized for winemaking and they are transported to the winery“crush pad” to be processed. The grapes may be destemmed or notdestemmed prior to Step B 104, depending upon the preferred method ofwine production, and loaded into the grape crusher. During Step B 104,the grapes are masticated so that the juice (must) can be separated fromthe skins, pulp and seeds. If the crushed grapes and must are to be usedin a white or rose style wine, they are immediately treated according tothe process of Step C 108.

If the crushed grapes and must are to be used in a red or “orange” stylewine, they are processed in Step B1 106, which entails loading thecrushed grapes and must into the fermentation tank where yeast is addedto initiate alcoholic fermentation. When the alcoholic fermentationprocess has terminated, the wine (“free run wine”) and the crushedgrapes are further processed in Step C 109. Typically, the free run wineis pumped off into tanks and the skins subjected to step C 108, wherethey are pressed to extract the remaining juice and wine. The press winemay optionally be blended with the free run wine at the winemaker'sdiscretion.

Thus, Step C 108 is applied to either the must derived from Step B 104(e.g, in the production of white wine) or to the alcoholic fermentedwine (free run wine) derived from Step B1 106 (e.g., in the productionof red wine). During Step C 108, the crushed grapes and either, theunfermented must derived from Step B 104 or the free run wine derivedfrom Step B1 106, are loaded into the press so that the must or free runwine can be squeezed from the marc 109 (solid matter). The must,destined to become a white wine, is loaded into a fermentation tankwhere yeast may be added to initiate alcoholic fermentation of the must.The press wine produced from Step C 108, which has now been separatedfrom the marc109, in step D 110 is inoculated with specific strains ofbacteria (lactobacter) to initiate malo-lactic fermentation to convert“crisp, green apple” malic acid to “soft, creamy” lactic acid to softenthe taste of the wine. The marc 109, which is traditionally treated asfood waste, is immediately removed from the “food preparation” area(crush pad).

As illustrated by FIGS. 2 and 5, the process of derivative-conversion,begins by transferring marc 109 to one or more processing containers 300(illustrated in FIG. 8) of this system to be processed during Step 1204, 206, 208, 210 (illustrated in FIGS. 3 and 6). The marc 109 isrehydrated with enough water to saturate the marc 109. After the berrieshave swollen, the saturated marc is ground into fine particulates and isthen inoculated with microbials to cause fermentation and dissolution ofsolid particles. This process can generally last for approximately 2 to6 weeks before proceeding to Step 2 218, 224.

During Step D 110 of the general winemaking process for white wine, themust is fermented until it turns into wine. As part of this step thespent yeast, tartaric acid, skin and pulp particulates settles to thebottom of the fermentation tank. As mentioned above, the press wine isusually subjected to malo-lactic fermentation during Step D, duringtraditional red wine making practices.

During Step E 112 of the winemaking process, the settled particulatesare separated from the wine by drawing the wine off of the top in aprocess known as racking and placed into oak, steel or ceramic vesselsfor aging. This particulate matter, suspended in a residual amount ofwine is referred to herein as first-rack lees 113. During traditionalwinemaking, the first-rack lees 113 is typically treated as food wasteand is immediately removed from “food preparation” area.

During the process of derivative-conversion, Step 2 214, 218, 224,incorporates the first-rack lees 113 into the processing container 300where it is emulsified with the biomass, which is then furtherfermented.

During Step F 114 of winemaking, the wine is aged for 2 to 60 months,depending on the grape varietal and winemaking technique. The wine isthen filtered to remove any residual lees, herein referred to assecond-rack lees 115, and placed into bottles, kegs or waterproof boxes.During traditional winemaking, the second-rack lees 115 typically istreated as food waste and is immediately removed from the “foodpreparation” area. During the process of derivative-conversion, however,as illustrated in FIG. 5 the second-rack lees 115 can be transferred tothe processing container 300 during Step 2A 214, 218 224, 228. 230, thebiomass is then further-fermented to generate a further-fermented purée232.

Thus, FIG. 2 illustrates that the first rack-lees 113 from Step E 112 isadded to the emulsion created during Step 1 204, 206, 208, 210 mixed andthen further fermented during Step 2 218, 224 until the fermentednutrient-rich product 226 achieves the desired flavour profile, nutrientvalue, and PH level. FIG. 5 illustrates that the first rack-lees 113from Step E 112 is added to the emulsion created during Step 1 204, 206,208, 210. mixed and then further fermented during Step 2 218, 224 untilthe second-rack lees 115 are ready, at which time they are transferredto the processing container and fermentation is continued until thefurther-fermented nutrient-rich product 232 achieves the desired flavourprofile, nutrient value, and PH level.

FIGS. 2 and 5 describe that at Step 3 234, the fermented purée 225 orfurther-fermented purée 232 are refined using filtration,homogenization, other techniques, or a combination of techniques. Atthis step, excess water is removed along with any undesirableparticulates or bi-nutrient-rich products, such as sulfur, bentonite,etc.

FIGS. 2 and 5 teach at Step 4 238 that refined nutrient-rich product 236is rendered shelf-stable through pasteurization or correction of PHlevel through further fermentation and thereby converted to stabilizednutrient-rich product 240.

FIGS. 2 and 5 illustrate that during Step 5 242, the stabilizednutrient-rich product 240 is packaged into consumer, culinary and/orindustrial vessels. It is then stored for shipment. The stabilizednutrient-rich product 240 could be in liquid, paste or powder formatbased on the needs of the end-user.

The Steps of the Derivitive-Conversion Process Described in GreaterDetail

FIGS. 4, 5, 7 and 8 outline the steps described above, including thesub-steps constituting the steps, intermediaries and nutrient-richproducts involved in embodiments of the system, methods processes, andnutrient-rich products made thereby. For example, Step 1204, 206, 208,210 comprises four sub-steps and various intermediates. The details foreach of the steps and sub-steps are described herein.

Step 1 Initial Acetic Acid Fermentation

As described in FIGS. 4 and 7, the marc 109 derived from the press istransferred to a processing container 300 of the system. Sub-step 202 isconducted by transferring the marc 109 from a collection vesseltypically used in a winery to collect marc 109 from the press andpouring the contents into a processing container 300. The marc 109 isthen rehydrated with an amount of water for a sufficient period of timeto allow the berries to swell. In one embodiment, a processing container300 is filled to 50-80% of its capacity, depending on the amount of marcavailable from the press. The addition space is reserved for lees and toprovide sufficient air above the cap of the mixture to accelerateaerobic fermentation.

Once the berries have swollen, the biomass is ground into a meal 205. Inone embodiment, the grinding process involves the use of a portablepureeing device that is inserted into the tank, which shreds the skinsand pulp, and cuts up the seed, allowing the microbial “cocktail” toattack the grape skin particles, pulp, seed pulp and bruised husk. Inone embodiment, a macerating pump, attached to the spigot that draws outthe material, passing it though a grinder, and then pumping it back intothe top of the container.

The meal 205 is then inoculated with with a microbial culture that maycomprise bacteria (e.g., acetic acid bacteria), enzymes and/or yeast tocause fermentation and dissolution of solid particles. Optionally, sugaror other natural sweetener may be added to accelerate the fermentation.The inoculated meal then is aeriated at a level that introduces enoughoxygen to allow aerobic fermentation to dominate all bioactivity. Theinoculated meal 205 is then allowed to rest and begin fermentation andthereby becomes fermenting meal 212. The processing containers arechecked periodically to monitor the progression of fermentation asassessed by the pH, the Brix level, optionally the temperature. Oneskilled in the art of fermentation would know which factors would bemost relevant to the type of nutrient-rich product they are seeking togenerate.

This process can generally last for 2 to 6 weeks. As this system isintegrated with the general winemaking process, as depicted in FIGS. 2and 5, the time-period for this process can depend upon the availabilityof the lees generated by the winemaking process.

Step 2: Lee Addition and Continued Fermentation

As described above, within the General Overview section, Step E 112 ofthe process of conventional winemaking, wherein either the must orpressed wine (red) is racked, generates first-rack lees 113. Thefirst-rack lees 113 is typically considered food waste and immediatelyremoved from the “food preparation” area. Wineries will either syphonthe wine from the top of the fermentation tank until the wine becomescloudy, or will drain the wine the wine from the bottom of the tankusing a filtration system to remove lees particles.

First-rack 113 lees can be collected in food safe containers and thenpoured over the fermenting meal 212 in a processing container 300 duringsub-step 214. During sub-step 218, the first-rack lees 113 and thefermenting meal 212 are emulsified to generate a purée 220. The purée isthen fermented in sub-step 224, during which the pH of the purée will beexpected to drop to below 3.5 pH.

Optional Inoculation of the Purée

One objective for this fermentation process is to establish how “sour”the ultimate fermented purée 225 should be allowed to become. Care mustbe provided regarding the levels of acetic acid present during thefermenting process. Ideally the optimal pH can be attained with thelactic acid remaining in the first-rack lees 113.

As described in the General Overview section, step D 110 of the generalred winemaking process, involves inoculating the press wine producedfrom Step C 108, with specific strains of bacteria (lactobacter) toinitiate malo-lactic fermentation to convert malic acid to lactic acidto soften the taste of the wine. If there isn't sufficient lactic acidremaining in the first-rack lees 113 after the malo-lactic fermentation,the purée 220 in processing container 300 is inoculated with a microbialsolution comprising acetic acid bacteria during sub-step 224 and allowedto ferment for approximately 60-90 days.

The fermentation process is monitored by periodically checking thePH/Brix ratio to maintain the pH of the purée 220 below 4.5 pH. Thisstage of the process is considered finished when the pH drops to anappropriate level, likely around 3.5 or possibly less. and the purée 220is considered completely converted to fermented purée 225. Theprocessing containers are checked periodically to monitor theprogression of fermentation as assessed by the pH, the Brix level,optionally the temperature. One skilled in the art of fermentation wouldknow which factors would be most relevant to the type of nutrient-richproduct they are seeking to generate.

Optional Storage-Lee-Addition Process

In one embodiment, illustrated in FIG. 5, an additional lee transferstep is included in the derivative-conversion process. During Step F 114of the conventional winemaking process, the wine is stored for aging,which generates second-rack lees 115. This embodiment entails collectingand transferring the second-rack lees 115 to processing container 300during sub-step 228.

This optional step is performed in a manner similar to the collectionand transfer of the first-rack lees 113, described above. In thiscollection and transfer step, however, care must be taken to ensure thatthe winery did not employ any filtration catalysts, such as bentonite(clay), egg whites (non-vegan), that would contaminate the finalnutrient-rich product. If these other substances are present, oneskilled in the art would know what appropriate applications would workfor the final nutrient-rich product that will eventually be produced andwhat should be avoided.

During sub-step 230, the processing containers are checked periodicallyto monitor the progression of fermentation as assessed by the pH, theBrix level, optionally the temperature, etc. One skilled in the art offermentation would know which factors would be most relevant to the typeof nutrient-rich product they are seeking to generate. Once the desiredfactors are present within the biomass, the further fermented purée 232will be refined according to Step 3 324

Step 3: Raw Nutrient-Rich Product Refinement Process

During Step 3 234, the fermented purée 225 or optionally, thefurther-fermented purée 232 is refined using filtration, homogenization,other techniques, or a combination of techniques in order to convert thefermented purée 225 or the further-fermented purée 232 into a refinednutrient-rich product 236. At this step, excess water is removed alongwith any undesirable particulates or bi-nutrient-rich products, such assulfur, bentonite, etc. One skilled in the art will appreciate thequalities and characteristics for the end nutrient-rich product, willknow what criteria to look for at this stage of the process and willmake the appropriate adjustments to generate an appropriate refinednutrient-rich product 236.

Some examples of steps that one skilled in the art may choose to employinclude the following.

-   -   During Step 3 234 the fermented purée 225 or the        further-fermented purée 232 will first be tested for bentonite,        sulphur and other food contaminants (likely before removal from        the winery)    -   In general, at this stage as described in more detail below        during the work flow section, the processing container(s) 300        will be collected by the Business to continue processing within        the business facility.    -   If contaminants are present, the fermented purée 225 or the        further-fermented purée 232 will be likely be processed in a        different manner that will be used only for livestock feed or        nutrient extraction.    -   If sulphur is present, the fermented purée 225 or the        further-fermented purée 232 is treated with a sulphur extractant        (eg hydrogen peroxide) to remove the sulfur. It then would be        homogenized, dewatered to a specific water %, and stored,        usually by varietal.    -   The stored material could optionally be blended with other        varietals (if necessary) to achieve a consistent flavour and        nutrient profile. There may be an optional homogenization step        after blending to stabilize to purée (keep the water from        separating). This step also may involve dewatering.

Once the objectives for the chemical characterization of thenutrient-rich product have been met, the material is considered to befinal nutrient-rich product 236.

Step 4 Refined Nutrient-Rich Product Stabilization Process

During Step 4 238, the refined nutrient-rich product 236 is renderedshelf-stable through pasteurization or correction of PH level throughfurther fermentation in order to convert the refined nutrient-richproduct 236 into a stabilized nutrient-rich product 240. One skilled inthe art will appreciate the qualities and characteristics for the endnutrient-rich product, will know what criteria to look for at this stageof the process and will make the appropriate adjustments to generate anappropriate stabilized nutrient-rich product 240.

There are applications for both a pasteurized purée (with no bioactivematerials) and a probiotic purée. High-pressure pasteurizationtechnology will normally be used to create a pasteurized nutrient-richproduct, although other current or future pasteurization techniques maybe employed. The bioactive purée will fermented to an approved pH levelfor sealed storage at room temperature, refrigerated temperature, and/orfrozen.

Step 5: Nutrient-Rich Product Packaging Process

During Step 5 242 the stabilized nutrient-rich product 240 is packagedinto consumer, culinary and/or industrial vessels in order to convertthe stabilized nutrient-rich product 240 into a packaged nutrient-richproduct 244. It is then stored for shipment. The stabilizednutrient-rich product 240 could be in liquid, purée, paste or powderformat based on the needs of the end-user. One skilled in the art willappreciate the qualities and characteristics for the packagednutrient-rich product 244, will know what criteria to look for at thisstage of the process and will make the appropriate adjustments togenerate an appropriate

The stabilized nutrient-rich product 240 will be optimized for extrusioninto sealed containers, which are specific to the industry andapplication using it. For example, the stabilized nutrient-rich product240 may extruded into consumer-sized sealed jars or bottles to generatepackaged nutrient-rich product 244 designed for home use. Alternatively,stabilized nutrient-rich product 240 may be extruded into 4 liter/1gallon sealed containers to generate packaged nutrient-rich product 244designed for culinary use. Alternatively, stabilized nutrient-richproduct 240 may be extruded into sealed 20 liter/5 gallon pails, or 1000liter Intermediate Bulk Containers to generate packaged nutrient-richproduct 244 designed or industrial food processing or pharmaceuticaluse.

The Nutrient-Rich Product

The nutrient-rich product can be used in food preparation, to:

-   -   a. reduce the amount of sodium in a food formula    -   b. Preserve dairy, meat, condiment and cereal nutrient-rich        products    -   c. Enhance the flavour of fruits, vegetables, and spices within        a food formula    -   d. Provide significant nutrient value to a food formula    -   e. Provide a source of yeast and other bacteria to cause the        leavening of bread    -   f. Provide a source of bacillus to cause the fermentation of        dairy nutrient-rich products    -   g. Provide a source of bacillus to cause the fermentation of        plant-based proteins

The nutrient-rich product may also be used to provide a medium forextraction of nutrients for pharmaceutical use in addition to provide amedium for topical applications in cosmetics or skin therapy.

Acetic Acid Bacteria

The steps of the derivative-conversion require inoculation of microbialformulation, comprising acetic acid bacteria. One skilled in the art offermentation would know which one(s) to select from the family of familyAcetobacteraceae.

Acetic acid bacteria (AAB) are a group of rod-shaped, Gram-negativebacteria which aerobically oxidize sugars, sugar alcohols, or ethanolwith the production of acetic acid as the major end nutrient-richproduct. This special type of metabolism differentiates them from allother bacteria.

The acetic acid bacteria consist of 10 genera in the familyAcetobacteraceae, including Acetobacter. Species of Acetobacter include:A. aceti; A. cerevisiae; A. cibinongensis; A. estunensis; A. fabarum; A.farinalis; A. indonesiensis; A. lambici; A. liquefaciens; A.lovaniensis; A. malorum; A. musti; A. nitrogenifigens; A. oeni; A.okinawensis; A. orientalis; A. orleanensis; A. papaya; A. pasteurianus;A. peroxydans; A. persici; A. pomorum; A. senegalensis; A. sicerae; A.suratthaniensis; A. syzygii;A. thailandicus; A. tropicalis; and A.xylinus. Several species of acetic acid bacteria are used in industryfor production of certain foods and chemicals.

The strains, which have been identified include: AcidibrevibacteriumAcidicaldus Acidiphilium Acidisoma Acidisphaera Acidocella AcidomonasAmeyamaea Asaia Belnapia Bombella Caldovatus CommensalibacterCraurococcus Crenalkahcoccus; Dankookia Ehoraea EndobacterGluconacetobacter; Gluconobacter Granulibacter Humitalea KomagatabacterKomagataeibacter Kozakia Muricoccus Neoasaia Neokomagataea NguyenibacterParacraurococcus; Parasaccharibacter. Although a variety of bacteria canproduce acetic acid, mostly members of Acetobacter, Gluconacetobacter,and Gluconobacter are used commercially. One skilled in the art wouldknow which one(s) to choose for the fermentation processes depending onthe final nutrient-rich product they desire to generate.

Lactic Acid Bacteria

Lactic acid bacteria (LAB) are an order of gram-positive, acid-tolerant,generally nonsporulating, non=respiring, either rod-shaped (bacilli) orspherical (cocci) bacteria that belong to the order Lactobacillales andshare common metabolic and physiological characteristics. Lactic acidbacteria are used in the food industry for a variety of reasons such asthe production of cheese and yogurt nutrient-rich products. The generathat comprise the LAB are at its core Lactobacillus, Leuconostoc,Pediococcus, Lactococcus, and Streptococcus, as well as the moreperipheral Aerococcus, Carnobacterium, Enterococcus, Oenococcus,Sporolactobacillus, Tetragenococcus, Vagococcus, and Weissella;.

The Processing Container

One embodiment of the processing container 300 is depicted in FIG. 8.The processing container 300 is a version of a food-grade intermediatebulk container (IBC), commonly referred to as an IBC tote, with aholding capacity of about 1,040 or 1,250 litres (275 and 330 US gal),capable of being stacked, which has been appropriately modified for usewith the methods and processes within this system 200.

One embodiment of a processing container 300 comprises and innercompartment 330 and an outer support structure 302. The outer supportstructure has four “walls” or cage-walls, (front 304, back 306, right308, left not shown or referenced), a rectangular base 310, which areall interconnected. The outer walls may be solid or cage-like, thelatter which is described in this non-limiting embodiment. The base 310may incorporate the function of a pallet 312 into the structure of theouter base 310 of the support structure.

The inner compartment 330 has four walls (only the right side is visiblein FIG. 8), a retractable lid 334. which is attached via hinging means337 and attached to the back wall of the inner compartment 330 of theprocessing container 300. A top access port 338 may be attached to theretractable lid 306, providing entry into the inner compartment 330,without having to retract the lid 334. The inner compartment 330 has alower access port 340, providing entry into the lower portion of theinner compartment 330.

The container has an aerator 360, attached to support means 362, thatgains access to the biomass through the lower access port 340, andforces air into the bottom of the container allowing air to percolate upthrough the mixture, encouraging aerobic fermentation. The aerator 360could either be powered via external electric power means 364 orsolar/battery power (not shown).

Optionally, multiple sensory devices to monitor temperature, pH leveland Brix, as well as other fermentation activities could be attached tothe container, and could optionally be monitored by using WiFi. Theoptional monitors would either be powered via external electric power orsolar/battery power.

The advantage of modified IBC totes is that most wineries already useunmodified totes and have equipment that allows them to move and stackthem on their property. The modified totes can be sealed to minimizefood contamination and placed in an external part of the property,either in or adjacent to the vineyard. One of the advantages ofin-vineyard placement is CO² sequestering by the vines and undergrowth.

One or more processing container(s) 300 are delivered to a winery forintegration into their winemaking and processing facilities andprocesses prior to crush. The numbers of containers 300 would be basedon the following ratio. Anticipated red grape tonnage×25%, which is theaverage percentage of marc 109 generated during Step C 108.

The Business Method

There are a number of different ways that the business method could bestructured to appropriately integrate the system, method, and processesdescribed herein in with the processes and facilities of a winery.

One embodiment as outlined in FIG. 12, entails the following steps. Atstep 602, a business delivers one or more processing container(s) 300 toa winery prior to crush. At step 604, winery staff transfers marc to oneor more processing container(s) 300. At step 606, winery staffrehydrates marc until berries swell, grinds the biomass into a meal,inoculates with microbials, and allows it to ferment at the wineryfacility. At step 608 winery staff transfers first-rack lees to the oneor more processing container(s) 300 comprising fermenting meal. At step610 winery staff emulsifies the first-rack lees and fermenting meal togenerate purée, inoculates the purée and allows it to ferment at wineryfacility. At step 612 winery staff monitors the progress of fermentingpurée and notifies the company when the fermentation has completed. Atstep 614, the business picks up the one or more processing container(s)300 and continues processing the fermented purée at the businessfacility.

In one embodiment, the business and the winery may choose to furtherprocess the fermented purée at the winery facility. In one embodiment,the business may choose to pick-up the processing containers prior toadding the first-rack lees 113, and conduct the further steps at thebusiness facility. In this embodiment, the business may choose tocollect the first-rack lees 113 from the winery when it is ready and addit to the fermenting meal 212 in the processing container(s) 300 at thebusiness facility. One skilled in the art would appreciate that thereare many different ways that this business relationship could bestructured to optimize the resources of the business and the winery,such that these embodiments are considered to be non-limiting examplesof how the work-flow of the business relationship could be designed.

One embodiment as described in Example 1, entails the businessdelivering processing containers to a winery prior to Step A 102 of thewinemaking process, and retrieving them after fermentation has beencompleted and fermented purée 225 has been generated within processingcontainer(s) 300. The business benefits by having the initial steps ofthe process conducted on site at the Winery. This point saves thebusiness from having to construct facilities on its location for Steps 1and 2, and can focus the design of the Business facilities to processingthe various nutrient-rich products under GRAS Conditions.

The business could pay the winery for:

-   -   a) The amount of properly fermented purée potentially adjusted        for:        -   1. Level of solids with purée        -   2. Type of varietal grapes used in the purée        -   3. Whether the grapes are organic        -   4. From a publicly recognized premium district, estate or            vineyard        -   5. Distance from the processing center    -   b) Additional work or services independent of the amount of        purée acquired, such as providing electrical power to the        location or providing access to vineyard property during off        hours.    -   c) Participating in nutrient-rich product development field        testing.

In addition, the winery benefits by:

-   -   a) reduction of waste and costs associated therewith;    -   b) possibly the acquisition of Carbon Credits    -   c) an additional revenue stream;    -   d) incorporation of named winery purée into premium foods; and    -   e) eliminating methane emissions caused by disposal in buried        landfills

The winery also benefits by diverting the substances from wastemanagement and disposal processes to the conversion process, becausethese bioactive by-products are subject to numerous local health,environmental and worker safety regulations in the post-productiontreatment and disposal. The impact of these regulations on the wineryare minimized.

Example 1

With reference to Table 1 presented in FIG. 11, this example describesone non-limiting manner in which the system, methods, processes andnutrient-rich products 200 made thereby can be incorporated into awinery producing grape wine. The Business is used to denote the businesspracticing the business methods described herein. The Winery is used todenote the wine production business within which this system, methods,and processes 200 is integrated.

Phase I. at the Winery

Table 1 shows the main stages in column 1, wherein the employees of theWinery (referred to herein as “cellar-hand”) are instructed to performtask(s) involved in the processes of this system, methods, processes200. The Business activities are presented in column 2, the Winery'sactivities in column 3, and estimated cellar-hand time per container incolumn 4. It is estimated that cellar-hand activities will be less thanone hour per container over the ≈140 days that the containers are onsite at the Winery.

Stage I: Pre-Crush

The Business drops processing containers 300 at the winery prior tocrush. The processing container 300 may already have an initialmicrobial cocktail encased in the interior compartment of the processingcontainer 300, which will become activated once water is added to theprocessing container 300.

The numbers of processing containers 300 could be based on the followingratio: anticipated red grape tonnage×25% (average percentage of marc109). For example, if a winery accepts 100 tons of red grapes, theBusiness could deliver 25 processing containers 300. Empty processingcontainers 300 could be stacked 2-3 high in a place where they leastimpact crush activities. One non-limiting example of where emptyprocessing containers 300 could be stored on the grounds of the Wineryis illustrated in FIG. 1.

Stage II During Press (Crush): Transfer Marc to Processing Container

Pursuant to sub-step 202, the cellar-hand is instructed to collect,transfer and deliver marc 109 generated during Step B 104 (crush), usinga collection bin that is normally used to collect marc 109 from thepress. Rather than discarding the marc 109 as per the usual winemakingprocess, wherein the marc 109 is usually dumped into a steel disposalbin, the cellar-hand is instructed to place the marc 109 into processingcontainers 300. The cellar-hand is instructed to fill the processingcontainer 300 until the marc 109 fills up to the 800-ltr level of theprocessing container 300, and then instructed to add sufficient water tosaturate and cover the marc 109, allowing the berries to swell as persub-step 204, and to close and secure the lid 334. This step generallyrequires less than 6 minutes to for the cellar-hand to perform, which isslightly longer than if they were to dump the marc 109 into a disposalbin as per the traditional process. After the berries have swelled, thehydrated marc may be optionally macerated using a motorized high-sheermixer that would break the seeds and skin. This accelerates thefermentation process and seed decomposition. This step may be delayeduntil after the lees are added.

If necessary, the cellar-hand can move and/or restack the processingcontainers 300 to minimize the impact of the presence of processingcontainers 300 on space requirements of the crush activities. Oneexample of where processing containers 300 can be placed is illustratedin FIGS. 1, 9 and 10. The biomass in the processing containers 300 isallowed to rest and begin fermentation from natural bacteria and/oradded microbials, while waiting for first-rack lees 113.

Stage III: Transfer First Rack Lees to Processing Container

When Step E of the winemaking process is completed, the cellar-hand isinstructed to collect and transfer the first-rack lees 113 to theprocessing container(s) 300, pursuant to sub-step 213 of the process.The time estimate for performing sub-step 213 is approximately 1-2minutes×19 ltr (five gallon) pails per container, which is generallytakes less amount of time than the usual time required to dispose offirst-rack lees 113. Once the lees are mixed into the marc, the combinedmaterial can be macerated using a high-sheer mixer, either for the firsttime if this did not happen in Stage II, of as secondary maceration tofurther break down the purée.

Stage IV. Prior to Microbial Fermentation

After sub-step 224 has been performed, the cellar-hand is instructed toplace processing container(s) 300 together in vineyard row(s) reasonablyclose to an electric power source. The cellar-hand is instructed toplace processing container(s) 300 where it would be convenient. andwhere CO2 sequestering could be maximized. The more containers that arelined up, the better as they will maintain internal heat. A protectivecover could then be placed over a series of the containers. The coverwill be tamper-resistant, will capture solar heart, and will retain heatfrom both the fermentation process and solar capture. They can also beused as a windbreak if desired. One example of where processingcontainers 300 can be placed is illustrated in FIGS. 1, 9 and 10. Thecellar-hand is instructed to let processing container(s) 300 ferment for60-90 days.

Stage V. During Microbial Fermentation

During this fermentation period, the cellar-hand is instructed toperiodically check the PH/Brix measurements of the fermenting purée inthe processing container(s) 300. Should the purée in a specificcontainer show signs of stabilization (pH and BRIX levels stay constantfor an extended period), the winery would advise the Business of thesituation.

Stage VI Post Microbial Fermentation

When the fermentation has been deemed to be finished, the Business picksup the processing container(s) 300 for processing at the Businessfacility. The cellar-hand will generally assist in this process, forexample, using winery forklifts to transfer the processing container(s)300 to the Business truck. This is likely 90-120 day after marc 109 ispressed. For example, if Merlot were pressed on November 1, thecontainer could be ready between February 1 and March 1. If CabernetSauvignon grapes were pressed December 1, the processing container 300would be ready for pick-up by the Business approximately March1-April 1. The processing container 300 would be ready for shipment fromthe winery to the Business at this time.

Phase II: at the Business Facility

The fermented purée 225 is processed at the Business facility usingBusiness staff In brief, the steps generally include that Businessstaff:

-   -   transfers the processing containers to Business facility;    -   empties the contents of processing container(s) 300 into a        blending tank with other varietals to achieve a consistent        blend;    -   emulsifies and homogenize the fermented purée 225 to mitigate        and/or remove oversized grape seed husk;    -   packages stabilized nutrient-rich product 240 new processing        container(s) 300; and    -   ship packaged nutrient-rich product 244 to one or more food        processor(s)

1. A system for integration into a wine-making facility and itsprocesses comprising: a. one or more processing containers, designed forease of use by winery staff, ease of storage during processing,efficacy, monitoring and security of a derivative-conversion process toat least the stage producing a fermented puree; b. instructions for therole of winery staff to participate in the process ofderivative-conversion to produce fermented puree; and c. optionally,microbial formulations designed to meet the fermentation objectives of anutrient-rich product generated by the derivative-conversion process. 2.The system according to claim 1 wherein the one or more processingcontainers comprises a version of a food-grade intermediate bulkcontainer which has been modified by generating a retractable lidtherein.
 3. The system according to claim 2 wherein the one or moreprocessing containers has been modified by incorporating aerating meansattached thereto.
 4. The system according to claim 2 wherein the one ormore processing containers has been modified by incorporating processmonitoring means attached thereto.
 5. A process for converting marc,first-rack lees and optionally second-rack lees derived from awinemaking process into refined bioactive products comprising the stepsof: a. transferring marc to a processing container; b. hydrating marcuntil berries swell; c. grinding hydrated marc to generate meal; d.optionally inoculating meal with a microbial formulation; e. fermentingthe inoculated meal to generate a fermenting meal; f. transferringfirst-rack lees to the processing container; g. emulsifying the firstfirst-rack lees and fermenting meal to generate a puree; h. optionallyinoculating the puree; i. fermenting said puree to generate a fermentedpuree; j. refining fermented puree to generate a refined nutrient-richproduct k. optionally stabilizing refined product to generate stabilizednutrient-rich product; and l. optionally packaging the stabilizednutrient-rich product.
 6. The process according to claim 5, wherein themicrobial formulation comprises Acetobacter, and/or Gluconobacter and/orother known acetic acid bacteria and/or fungus inoculants
 7. The processaccording to claim 5, wherein enzymes may be added to the fermentingmeal.
 8. The process according to claim 5, wherein methane emissionsthat would otherwise be caused by disposal of marc and lees in buriedlandfills is eliminated or significantly reduced.
 9. A nutrient-richproduct substantially produced by the process of claim
 5. 10. Thenutrient-rich product of claim 9 comprising varietal grape skin,varietal grape seed, and winemaking sediment.
 11. A method of convertingwinery derivatives into nutrient-rich products comprising the steps of:a. a business delivers one or more processing containers to a wineryprior to crush; b. winery staff transfers marc to one or more processingcontainer(s); c. winery staff rehydrates marc until berries swell,grinds the biomass into a meal, inoculates with microbials, and allowsit to ferment at the winery facility; d. winery staff transfersfirst-rack lees to the one or more processing containers comprisingfermenting meal; e. winery staff emulsifies the first-rack lees andfermenting meal to generate puree, inoculates the puree and allows it toferment at winery facility; f. winery staff monitors the progress offermenting puree and notifies the company when the fermentation hascompleted; and g. the business picks up the one or more processingcontainers and continues processing the fermented puree at the companyfacility.
 12. The method according to claim 11, wherein the microbialformulation comprises Acetobacter, and/or Gluconobacter and/or otherknown acetic acid bacteria and/or fungus inoculants
 13. The methodaccording to claim 11, wherein enzymes may be added the fermenting meal.14. The method according to claim 11, wherein methane emissions thatwould otherwise be caused by disposal of marc and lees in buriedlandfills is eliminated or significantly reduced.
 15. A nutrient-richproduct substantially produced by the method of claim
 11. 16. Thenutrient-rich product of claim 15 comprising varietal grape skin,varietal grape seed, and winemaking sediment.